How to Move Shackles in 3"

The only info I've found about this is that it's "easy" compared to installing the front boxes. I guess it depends on the tools and experience one has. So, I thought I'd add my method, maybe it'll help someone searching this in the future.

I decided to use the USCT brackets that I linked to in my first post.

I found that they don't slide onto the frame rail properly because of the way the original hanger brackets are spot welded to the rail, making the frame rail thicker, thus not allowing the bracket to slide back against the surface where the two bolts that held the original shackle bracket go. I couldn't see a good way to remove that spot welded tab, so I used a spacer to hold the brackets out a bit. I installed the springs just by their front spring eyes, just to be sure the angle of the shackles is still okay.

I cleaned up the area where the brackets are going to be with a die grinder and a bullet wheel. Then I used machinists ink so I could scribe the holes for the sleeves onto the frame rails.

Then I removed the brackets so that I could make the holes. The holes no longer interfere with those welded inserts because the new bracket location moves them in front of them.

The holes on the outside of the rail aren't too hard to do. I used a 90* adapter in my drill and worked my way up until I had 1/2" holes, which is the largest drill I have. (It could be done without using the 90*.) The sleeves are about 1" (or so) outside diameter, so I used my die grinder with a die burr to get close to the scribe mark. I then used the bullet grinding wheel to finish it, using the bushing as a guide.

The inner holes are a different story. The spare tire well limits the access for drilling and grinding. I was able to drill the 1/2" holes (progressively from a starter drill on up) on an angle because they were just starter holes for the grinder. But I had to stop and order a right angle grinder so that I can finish opening the holes.

I will update as to how I finish it up. I still have to figure how to weld them in without the weld interfering with the bushing movement.